The gearbox oil should be changed every 40,000 miles.

The manual gearbox on a 1998, 1.9D takes around 1.85-2 litres of 75W80 oil.

As always, take care when working under a vehicle. Apply the handbrake, put the vehicle in 1st gear, chock the rear wheels and use axle stands. It's probably wise to wear safety specs to as splashes of oil and other engine bay crud are not fun on the eyeballs

Warmer gearbox oil drains quicker so you may want to do this after a run out.

Raise up the front of the vehicle (either jack or raise on ramps, etc).

You will need an 8mm square drain plug key and a torque wrench if you're doing things by the book. Also handy is a funnel with a flexible filler pipe. A blowtorch is optional to rework the copper washer, or you may just replace it with a new one.

  • Undo the drain plug carefully, being ready to catch the 2 litres of oil which will fall out. Mind that you don't lose the copper-crush washer in the old oil.
  • Whilst the oil is draining, take the copper washer aside and use a blowtorch to heat it until it is cherry red then drop it into some cold water. This should anneal it so that it can be used again.
  • Clean the plug, add the copper washer (or a new one) and refit in to the empty gearbox.
  • Tighten the plug to 30Nm

At this point the vehicle may be dropped again, however, if you drop anything whilst working in the engine bay then you may need to get back under again.


Prepare to Refill

The gearbox filler is somewhat inaccessible on the side of the casing. An easier option is to use the breather valve on the top. It helps to lift the air-filter box up and away from the work area.


Locate and remove the Breather Valve

The breather valve is made of black plastic with a white plastic loose (but captive) cap on the top of this. Take care unscrewing and re-tightening this valve as the plastic can be easily over-torqued and damaged.


Refill with Oil

It's easier to use a funnel with a flexible filler pipe to refill the oil. When you have added the required amount (I used 2 litres) then replace the breather valve (be careful with the tightening), refit the air filter box, close the bonnet and carefully lower the vehicle off its stands and jack to the ground.